Reinforced elastomer panel

ABSTRACT

A reinforced elastomer panel (100) has a first rigid member (104) with an edge (116) attached to a first end of an elastomer panel (114). The first rigid member (104) has a removable plate (106) that provides access to a cavity (108). Attached to the first rigid member (104) is a reinforcing member (102) that extends through the elastomer panel (114). A second rigid member (118) has an edge attached to a second end of the elastomer panel (114).

FIELD OF THE INVENTION

The present invention relates generally to the field of flexible elasticpanels and more particularly to the field of reinforced elastomerpanels.

BACKGROUND OF THE INVENTION

Reinforced elastomer panels are applicable for use on aircraft toeliminate gaps around control surfaces. Open gaps result in turbulenceand leakage that result in reduced effectiveness of the control surface.A prior art reinforced elastomer panel 50 is shown in FIG. 1. Theelastomer panel 50 has a rod block 52 attached along one edge to anelastomeric skin 54. The elastomeric skin 54 is capable of stretching toup to 100% of its unstressed length. A plurality of rods 56 arepermanently attached to the rod block 52 and are allowed to slide freelyinside the elastomeric skin 54. The rods 56 provide the elastomeric skin54 with a curvilinear shape when the elastomer panel 50 is elongated,deflected or twisted.

A second rod block 58 is attached to an opposite edge of the elastomericskin 54. The second rod block 58 has a plurality of holes through whichthe plurality of rods 56 are allowed to slide freely. Both the rod block52 and the second rod block 58 have attachment provisions 60, forattaching the elastomer panel 50 to the surface of an aircraft.

However, a number of problems have been found with the prior art. Therod blocks 52, 58 are made of solid metal and are heavy. In addition,the holes have to be drilled through the rod blocks. Because of thelength of these holes the drill bits break often, making this anexpensive slow process. Another problem that has occurred is that therods 56 tend to rub along the holes in the rod block 58. The rods rub asthey slide along the rod block 58, when the elastomeric panel 50 iselongated or deflected as shown in FIG. 2. This significantly reducesthe cycle life of the panel and results in the whole panel 50 having tobe replaced.

Thus there exists a need for a reinforced elastomer panel that overcomesthese and other problems.

SUMMARY OF THE INVENTION

A reinforced elastomer panel that overcomes these and other problems hasa first rigid member with an edge attached to a first end of anelastomeric panel. Also attached to the first rigid member is areinforcing member that extends through the elastomer panel. A secondrigid member has an edge attached to a second end of the elastomerpanel. A flexible inelastic strip runs along an attachment line betweenthe first rigid member and the elastomer panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a prior art reinforced elastomer panel;

FIG. 2 is a side view of a prior art reinforced elastomer beingelongated and deflected;

FIGS. 3A & B are cross sectional side views of a reinforced elastomerpanel according to the invention;

FIG. 4 is a top view of the reinforced elastomer panel of FIGS. 3A & B;

FIG. 5 is a top view of a reinforcement member used with the reinforcedelastomer panel of FIGS. 3A & B;

FIG. 6 is a top view of a rod block used with the reinforced elastomerpanel of FIGS. 3A & B;

FIG. 7 is a cross sectional view of a portion of another embodiment of areinforced elastomer panel according to the invention;

FIGS. 8A & B are perspective views of the reinforced elastomer panel ofFIG. 7 illustrating a method of repairing tears in the elastomer;

FIGS. 9A, B & C are different views of another embodiment of astructural block for a reinforced elastomer panel according to theinvention;

FIG. 10 is a cross sectional view of another embodiment of a structuralblock for a reinforced elastomer panel according to the invention;

FIGS. 11A & B are different views of another embodiment of a structuralblock for a reinforced elastomer panel according to the invention;

FIG. 12 is a partial exploded view of a method of making anotherembodiment of a structural block for a reinforced elastomer panelaccording to the invention;

FIG. 13 is a partial end view of structural block of FIG. 12;

FIG. 14 is a partial exploded view of a method of making anotherembodiment of a structural block for a reinforced elastomer panelaccording to the invention;

FIG. 15 is an exploded view of a method of making another embodiment ofa structural block for a reinforced elastomer panel according to theinvention;

FIG. 16 is a cross sectional view of the structural block of FIG. 15;

FIGS. 17A & B are different views of another embodiment of a structuralblock for a reinforced elastomer panel according to the invention;

FIG. 18 is a cross sectional view of an elastomer panel;

FIG. 19 is a partial cross sectional view of another embodiment of areinforced elastomer panel according to the invention;

FIG. 20 is a cross sectional view of another embodiment of a reinforcedelastomer panel; and

FIG. 21 is a cross sectional view of the rod block of the reinforcedelastomer panel of claim 20.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 3A & B show a reinforced elastomer panel 100 that allows easyreplacement of any of the plurality of reinforcing members 102. Thereinforced elastomer panel 100 has a first block 104 with a removableplate 106 that provides access to a plurality of cavities 108. Theplurality of cavities 108 contain the plurality of reinforcing members102. An access hole 110 in each of the cavities 108 of the first block104 allows the reinforcing members 102 passage into one of the pluralityof holes 112 in an elastomer sheet 114. The elastomer sheet 114 isattached to an interior edge 116 of the first block 104. A second block118 is attached to the other end of the elastomer sheet 114. The secondblock 118 has a plurality of voids 120 through which the plurality ofreinforcing members 112 extend.

FIG. 4 is a top view of the reinforced elastomer panel 100. In this viewthe removable plate 106 can be seen to extend along the complete lengthof the first block 104. Attachment provisions 119 are shown ascountersunk. A screw would then hold the removable lid 106 to the firstblock 104. Other attachment provisions will be obvious to those skilledin the art. Any such attachment provisions are considered part of theinvention as defined in the appended claims. The description will notdiscuss attachment provisions for the other embodiments of thereinforced elastomer because a number of attachment provisions arepossible and add nothing to the understanding of the invention.

FIG. 5 shows a reinforcing member 102. The first end 122 of thereinforcing member 102 has a keyed flanged bushing (flanged bushing) 124attached to it. The keyed flanged bushing 124 fits inside the cavity 108formed by an interior surface (wall) of the removable lid 106 and thecavity 108. The second end 126 slides into the hole 112 in the elastomersheet 114 and through the cavity 120 in the second block 118. Theflanged bushing 124 keeps the reinforcing member 102 secured inside thecavity 108. When the reinforcing member 102 needs to be replaced, theremovable lid 106 is removed (see FIG. 3B). Once the removable lid 106is removed, the reinforcing member 102 is pried out of the first block104, via screwdriver slots 109. A replacement reinforcing member 102 isthen inserted into the cavity 108.

FIG. 6 shows the first block (base) 104 with the removable plate 106removed. The plurality of cavities 108 are seen where the removableplate would be. The cavities (hollow space) 108 match the shape of theflanged bushing 124. As a result this embodiment allows for easyreplacement of the reinforcing members.

FIG. 7 shows a partial cross section of another embodiment of areinforced elastomer panel 150. The reinforcing member is not shown inthe figure. A common problem with the prior art designs was tearingalong the top and bottom attachment line (bond line) 152, 154. When thepanel 150 is deflected downward, a large amount of stress occurs alongthe top attachment line 152. Over time this extra stress leads totearing along the attachment line (bond line) 152. To alleviate thisstress a flexible inelastic strip 156, 158 is placed over the bond line152, 154 between the first rigid member 160 and the elastomer panel 162.This reduces the stress at the bond line and spreads the stress over agreater region.

The flexible inelastic strip 156, 158 can be made from fiberglass,reinforced cloth, metal sheets, screens or other non-stretching fabrics.In one embodiment the flexible inelastic strip is attached with anelastomer bonding agent, such as a silicon adhesive (adhesive). Inanother embodiment the flexible inelastic strip is molded in place whenthe elastomer is attached to the first rigid member 160.

FIGS. 8A & B show a method of repairing a tear 164 in the elastomersheet 162. The embodiment shown in FIG. 8A shows the flexible inelasticstrip (strip of flexible material) 156 covering the bond line betweenthe second rigid member 166 and the elastomer panel 162. The tear 164 iscovered with a piece of the flexible inelastic strips 168 in FIG. 8B.The elastomer panel 162 is repaired by first removing any stress fromthe reinforced panel 150. Next an area on the elastomer surface aroundthe tear (damaged area) 164 is prepared for an adhesive. This caninclude cleaning the elastomer and other steps such as roughing up thearea. Next an adhesive is place don the area. The flexible inelasticpatch 168 is then placed over the adhesive. Finally, the adhesive iscured. The flexible inelastic strip keeps the tear from spreading.

FIGS. 9A, B & C show another embodiment of a rod block for a reinforcedelastomer panel. The structural block 180 has a plurality of countersunkholes 182 for attachment. The structural block (second structural block)180 has a sleeve(s) 184 that extends into the structural block 180. Thesleeves 184 have flared ends 186 that allow the reinforcing members(flexible rib) to slide more easily inside the structural block 180. Inone embodiment the sleeve 186 is made of steel, brass, beryllium,copper, phosphor-bronze or some other lubricant compatible material. Inanother embodiment the sleeves are coated with a lubricant, such as oil,silicone or coated with Teflon®. The fluted ends (flared ends) 186 ofthe sleeves 184 are encased in the elastomer panel. The structural block180 is a metal box 188. In one embodiment the metal box 188 is formedfrom a pair of formed sheets of metal. The sheets of metal are attachedto each other and holes are drilled for the sleeves 184. The inside ofthe metal box 188 is filled with a polymer material 190. In oneembodiment the polymer material (light weight polymer material) 190 is alight weight foam material (foam filler).

A reinforced elastomer panel formed with the structural block 180 hasthe advantage of being light weight and the sleeves 184 reduce the wearand fraying of the rods. FIG. 10 shows an even lighter weightembodiment, where the one side (open side) 192 of the metal box is open.The polymer material 190 in both embodiments provides structuralintegrity and allows some flexing of the sleeves 184.

FIGS. 11A & B are similar in design to the structural blocks in FIGS. 9& 10, except the metal box 188 is extruded. Also the metal box 188 has astrut (internal strut, reinforcing wall) 194, that provides additionalstructural stiffness to the structural box 180.

FIG. 12 shows a method of forming another embodiment of a structuralblock 200 for a reinforced elastomer panel. The structural block 200 hasa top rigid plate 202, a bottom rigid plate 204 with a sleeve 206between them. A polymer material 208 is used to bond the top rigid plate202 to the bottom rigid plate 204. In one embodiment the polymermaterial 208 is a sheet adhesive or elastomer. A completed version ofthe structural block 200 is shown in FIG. 13. In one embodiment the toprigid plate 202 is made from metal. Other materials are contemplated forthe rigid plates 202, 204, such as hard rubber, composites and plastics.In another embodiment the rigid plates have grooves 210 that the sleeves206 sit in.

FIG. 14 is an embodiment of a structural block 220. In this embodimentthe structural block 220 is a metal block 222 with a plurality of holes224 drilled in the metal block. A plurality of sleeves 226 are bondedinside the plurality of holes 224.

FIG. 15 shows a method of making another embodiment of a structuralblock 230. The structural block 230 has a top metal plate 232 and abottom metal plate 234. A plurality of calendared elastomer pieces 236are placed between the metal plates 232, 234. A plurality of sleeves 238are inserted between the calendared elastomer pieces 236. The lay-up isthen processed to cause the elastomer pieces 236 to adhere to the plates232, 234 and the sleeves 238. In addition the elastomer pieces 236 fusetogether. FIG. 16 shows a cross section through one of the sleeves of acompleted structural block 230.

FIGS. 17A & B show another embodiment of a structural block 250. In thisembodiment the structural block 250 is molded. This can be accomplishedby cast or injection molding. In this case the structural block 252 ismade of an injection molded material, such as plastic, epoxy, or longfiber reinforced thermoplastic. The structural block 252 includes aplurality of sleeves (plurality of sacrificial bushings) 254. In anotherversion the structural block 250 is formed as a composite lay-up.

FIG. 18 is shows an elastomer panel 300. The elastomer panel 300 doesnot have any reinforcing members. In cases where an elastic panel isneeded, but the panel will only undergo elongation or bending, noreinforcing members will be necessary for small spans. As a result theweight of the elastomer panel 300 can be significantly reduced. Theelastomer sheet 302 is attached to a rigid block 304 at a first end andto a second rigid block 306 at a second end. The rigid blocks 304, 306are L shaped to reduce the weight. In addition, the blocks 304, 306 canbe formed of metal, plastic, rubber, or composites (composite material)depending on the weight to strength tradeoffs for the application. Inthe embodiment shown the elastomer panel 300 is attached to the aircraftby bolts 308.

FIG. 19 shows a partial view of another embodiment of a reinforcedelastomer panel 320. The rigid structural block 322 has attachmentprovisions 324. In this embodiment the sleeve 326 extends into theelastomer panel 328. The reinforcing rod 330 slides inside the sleeve326. This embodiment has the advantage that rods 330 do not extendbeyond the rigid structural block 322.

FIGS. 20 & 21 show a partial view of another embodiment of a reinforcedelastomer panel 350. In this case the rigid block 352 is a metal box(metal rectangular container) 354 attached to an elastomer sheet 354. Aplurality of reinforcing members 356 extend from the rigid block 352into the elastomer sheet 354. A corrugated rigid sheet 358 is insertedinto the end 360 of the metal box 352. The corrugated rigid sheet formsa plurality of cavities 362 for the reinforcing members 356. In anotherembodiment, the sleeves are inserted into the cavities.

Thus there has been described a reinforced elastomer panel that is lightweight, allows for easy replacement of broken reinforcing members andreduces the wear and fraying of the reinforcing members. While theinvention has been described in conjunction with specific embodimentsthereof, it is evident that many alterations, modifications, andvariations will be apparent to those skilled in the art in light of theforegoing description. Accordingly, it is intended to embrace all suchalterations, modifications, and variations in the appended claims.

What is claimed is:
 1. A reinforced elastomer panel, comprising:a firstblock having a removable plate and a plurality of cavities, each of theplurality of cavities having an access hole; a plurality of reinforcingmembers, each of the plurality of reinforcing members having a first endand a second end, the first end fitting into one of the plurality ofcavities in the first block; an elastomer sheet attached to an interioredge of the first block, the elastomer sheet having a plurality of holesrunning along its length, each of the plurality of holes abutting one ofthe plurality of cavities in the first block and having one of theplurality of reinforcing members extending along its length; and asecond block attached to the elastomer sheet and having a plurality ofvoids, each of the plurality voids having one of the plurality ofreinforcing member extending along its length.
 2. The reinforcedelastomer panel of claim 1, wherein the plurality of cavities are moldedinto the first block.
 3. The reinforced elastomer panel of claim 1,wherein the first block is made of a metal.
 4. The reinforced elastomerpanel of claim 1, further including a flanged bushing attached to thefirst end of each of the plurality of reinforcing members.
 5. Thereinforced elastomer panel of claim 1, wherein an interior surface ofthe removable plate forms a wall of the plurality of cavities.
 6. Thereinforced elastomer panel of claim 1, wherein the second block is madefrom a composite material.
 7. The reinforced elastomer panel of claim 6,further including a plurality of sacrificial bushings, one of theplurality of sacrificial bushings extending along the length of one ofthe plurality of voids.
 8. The reinforced elastomer panel of claim 7,wherein each of the plurality of sacrificial bushings is made of amaterial selected from the group of brass, copper, steel, andphosphor-bronze.
 9. The reinforced elastomer panel of claim 8, furtherincluding a lubricant inside each of the plurality of sacrificialbushings.